High Activity Ethylene Polymerization Catalyst Preparation
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Solution Overview
Problem
Current Ziegler-Natta catalysts for polyolefin polymerization often produce low molecular weight by-products and broad molecular weight distribution polymers, which are not suitable for industrial applications, and existing methods to improve catalyst activity are complex and costly, involving multiple steps and high temperature treatments.
Innovation Solution
A method for preparing high activity ethylene polymerization catalysts by adding magnesium halide to an alcohol solvent, precipitating with an organo compound, and treating with a titanium compound and organoaluminium compound at low temperatures (0-60°C) with a controlled Al/Ti mole ratio, simplifying the process and reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional Ziegler-Natta catalyst is used for polyolefin polymerization, then the catalyst is suitable for polymerization process, but low molecular weight polyolefin or wax as by-product is formed
Solution Approach 1:
The patent modifies the catalyst composition parameters by incorporating specific electron donors (silicon-based compounds) and organometallic compounds in controlled ratios, changing the chemical environment of the catalyst to suppress by-product formation while maintaining polymerization activity
Solution Approach 2:
The patent creates a composite catalyst system combining multiple components: Ziegler-Natta catalyst, electron donors, and organometallic compounds. This composite structure synergistically improves catalyst performance by reducing harmful by-products while maintaining reliability
2Productivity
If conventional Ziegler-Natta catalyst is used, then the catalyst is active for polymerization, but broad molecular weight distribution polymer is produced
Solution Approach 1:
The patent introduces electron donors that create localized electronic environments around different catalyst sites, modifying the activity of each site to produce more uniform polymer chains with narrower molecular weight distribution while maintaining overall high catalyst activity
Solution Approach 2:
By adjusting the type and amount of electron donor and organometallic compound, the patent optimizes the chemical parameters of the catalyst system to achieve both high productivity and narrow molecular weight distribution, resolving the contradiction between activity and precision
3Productivity
If existing methods are used to improve catalyst activity, then catalyst performance is enhanced, but the process becomes complex with many steps and high temperature treatment
Solution Approach 1:
The patent combines multiple catalyst components (electron donor, organometallic compound, and Ziegler-Natta catalyst) into a single integrated preparation process that occurs at low temperatures, eliminating the need for separate high-temperature treatment steps and reducing overall process complexity while enhancing catalyst activity
4Productivity
If existing methods are used to improve catalyst activity, then catalyst performance is enhanced, but production cost increases
Solution Approach 1:
The patent employs relatively inexpensive electron donors and organometallic compounds that can be used in controlled amounts during catalyst preparation. These components enhance catalyst activity without requiring expensive materials or energy-intensive high-temperature processing, thereby improving productivity while controlling production costs
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method results in a catalyst with high activity and narrow molecular weight distribution polymers, improving mechanical properties and reducing the formation of low molecular weight by-products, while being easier to perform and more cost-effective than existing methods.
Implementation Method 1
treating the catalyst obtained from (c) with organoaluminium compound selected from trialkylaluminium, alkylaluminium alkoxide, alkylaluminium halide, or a mixture thereof at temperature ranging from 0 to 60 °C for 2 to 5 hours
Implementation Method 2
adding magnesium halide into alcohol solvent selected from ethanol, isopropanol, butanol, hexanol, 2-hexanol, octanol, or a mixture thereof
Implementation Method 3
precipitating solution from (a) in solution of organic solvent containing organo compound of group III element
Data Source
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AI summary
The present invention relates to a method for preparing a high activity olefin polymerization catalyst, which is easy to be produced, reducing complicated steps, and can be produced at low temperature, wherein said method comprising the following steps: • (a) adding a magnesium halide into an alcohol solvent; • (b) precipitating the solution obtained from (a) in a solution of an organic solvent containing an organo compound of group III element; • (c) adding a titanium compound into the mixture obtained from (b) to obtain a catalyst; • (d) treating the catalyst obtained from (c) with an organoaluminium compound at a temperature ranging from 0 to 60 °C for 2 to 5 hours, wherein the mole ratio of aluminium to titanium (Al/Ti) for treatment is in a range of 1 to 30.